UAS Automotive Technology Course Syllabus AUTO 152 – Brake Systems Spring 2012 - Section J01 4 credits Instructor: Phone: Email: Ray Kaiser (907)723-1002 kaiserray@yahoo.com Course dates: Wednesday, January 18 – Wednesday, May 2, 2012 Times: Wednesday, 6:00 PM – 8:00 PM Saturday, 9:00 AM – 1:00 PM Location: Technology Education Center, Room 216 Course Homepage: http://www.uas.alaska.edu/online/ Course Description: Theory, diagnosis, and repair of automotive brake systems. Grading Method: Letter Prerequisites: AUTO 121 or concurrent enrollment Course Objectives: Upon successful completion of this course, the student will be able to demonstrate ability to perform the following tasks as specified by NATEF (National Automobile Technicians Education Foundation); Task # V.A.1 Priority P-1 V.A.2 P-1 V.A.3 P-1 V.A.4 P-1 Task Description Complete work order to include customer information, vehicle identifying information, customer concern, related service history, cause, and correction. Identify and interpret brake system concern; determine necessary action. Research applicable vehicle and service information, such as brake system operation, vehicle service history, service precautions, and technical service bulletins. Locate and interpret vehicle and major component identification numbers. V.B.1 P-1 V.B.2 P-1 V.B.3 P-1 V.B.4 V.B.5 P-1 P-2 V.B.6 P-1 V.B.7 V.B.8 P-2 P-2 V.B.9 V.B.10 P-1 P-3 V.B.12 V.B.13 V.C.1 P-1 P-1 P-1 V.C.2 P-1 V.C.3 V.C.4 P-1 P-1 V.C.5 V.C.6 P-2 P-2 V.C.7 P-1 V.D.1 P-1 V.D.2 P-1 V.D.3 P-1 V.D.4 P-1 V.D.6 P-1 Diagnose pressure concerns in the brake system using hydraulic principles (Pascal’s Law). Measure brake pedal height, travel, and free play (as applicable); determine necessary action. Check master cylinder for internal/external leaks and proper operation; determine necessary action. Remove, bench bleed, and reinstall master cylinder. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging or wear, tighten loose fittings and supports; determine necessary action. Replace brake lines, hoses, fittings, and supports. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). Select, handle, store, and fill brake fluids to proper level. Inspect, test, and/or replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. Bleed and/or flush brake system. Test brake fluid for contamination. Diagnose poor stopping, noise, pulling, grabbing, dragging, or pedal pulsation concerns; determine necessary action. Remove, clean, inspect, and measure brake drums; determine necessary action. Refinish brake drum; measure final drum diameter. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble. Inspect and install wheel cylinders. Pre-adjust brake shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings. Install wheel, torque lug nuts, and make final checks and adjustments (drum brakes) Diagnose poor stopping, noise, pulling, grabbing, dragging or pulsation concerns; determine necessary action. Remove caliper assembly; inspect for leaks and damage to caliper housing; determine necessary action. Clean and inspect caliper mounting and slides/pins for operation, wear, and damage; determine necessary action. Remove, inspect, and replace pads and retaining hardware; determine necessary action. Reassemble, lubricate, and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks. V.D.7 P-1 V.D.8 V.D.9 V.D.10 V.D.11 V.D.12 P-1 P-1 P-1 P-3 P-1 V.D.13 P-2 V.E.1 V.E.2 V.E.3 P-2 P-1 P-1 V.E.5 V.F.1 P-3 P-1 V.F.2 P-1 V.F.3 P-2 V.F.4 P-1 V.F.6 V.F.7 V.F.8 V.G.1 P-1 P-1 P-1 P-1 V.G.2 P-2 V.G.5 V.G.8 P-1 P-3 V.G.10 P-3 Clean, inspect, and measure rotor thickness, lateral runout, and thickness variation; determine necessary action. Remove and reinstall rotor. Refinish rotor on vehicle; measure final rotor thickness. Refinish rotor off vehicle; measure final rotor thickness. Retract caliper piston on an integrated parking brake system. Install wheel, torque lug nuts, and make final checks and adjustments (disc brakes). Check brake pad wear indicator system operation; determine necessary action. Test pedal free travel; check power assist operation. Check vacuum supply to vacuum-type power booster. Inspect the vacuum-type power booster unit for leaks; inspect the check valve for proper operation; determine necessary action. Measure and adjust master cylinder pushrod length. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine necessary action. Remove, clean, inspect, repack, and install wheel bearings and replace seals; install hub and adjust bearings. Check parking brake cables and components for wear, binding, and corrosion; clean, lubricate, adjust or replace as needed. Check parking brake and indicator light system operation; determine necessary action. Replace wheel bearing and race. Inspect and replace wheel studs. Remove and reinstall sealed wheel bearing assembly. Identify and inspect electronic brake control system components; determine necessary action. Diagnose poor stopping, wheel lock-up, abnormal pedal feel, unwanted application and noise concerns associated with the electronic brake control system; determine necessary action. Bleed the electronic brake control system hydraulic circuits. Diagnose electronic brake control system braking concerns caused by vehicle modifications (tire size, curb height, final drive ratio, etc.). Describe the operation of a regenerative braking system. Textbook: Automotive Brake Systems (Fifth edition) by James D. Halderman. This textbook comes packaged with a worktext, and is available in the bookstore in the Mourant building at the main campus. Materials needed for class: Safety glasses (required) – safety glasses will be worn at all times in the Automotive Lab. You can purchase a set of approved UVEX safety glasses at the campus bookstore. Note that there are two types available; regular and ones made to go over eyeglasses. Coveralls (optional – how dirty do you want to get?) Personal padlock (optional) – personal lockers are available to you, but locks must come off and the locker emptied at the end of the semester. Note: You will NOT be required to purchase hand tools to participate in this class. All tools will be provided for you. It is important to note, however, that you are expected to treat the program’s hand tools with respect, and be sure to return them as you found them. This means wiping them clean and making sure they go back in their proper place. Grading: Every student needs to know exactly how they will be graded during the course. There are four areas that make up your grade in AUTO 152: 1. 20% of your grade is determined by attendance in lab and classroom sessions. Typically, I will assign two points per session. A student will receive one point if they are on time for class, and one more will be assigned if they stay until the end of class. 2. 40% of your grade is determined by completion of lab assignments. Specific skills are taught during the lab sessions of the class and you will receive credit for these by completing the lab worksheets. 3. 40% of your grade is based on your performance on quizzes and the midterm and final exams. Grades will be assigned based on the following percentages: A AB+ B BC+ C CD+ D DF 93-100% 90-92% 86-89% 83-85% 80-82% 76-79% 73-75% 70-72% 66-69% 63-65% 60-62% 60% and below The bottom line is, you cannot do well unless you come to class consistently. Coming late or not at all is the quickest way to put yourself in the hole. Online Gradebook: Student grades are maintained in a secure online environment. You can access your current grade and the scores of all assignments by going to the course home page and entering your personal access code under “Assignments.” Homework: You are assigned homework for every class meeting. For instance, if the content of meeting three was covered during one session, it is expected that you will do the homework for that meeting and have it ready for class the following meeting. Answer keys for the homework will be available at the course homepage at UAS Online. While no credit is extended for completion of the homework, your performance on quizzes and exams will be in proportion to your effort in completing the homework assignments! Conduct in the lab: The Auto lab is an industrial environment and safety is the number one priority. Having said that, horseplay is strictly forbidden in the lab. Students are expected to conduct themselves in a professional, courteous manner at all times. Many of the resources must be shared and everyone is expected to cooperate with others as best they can. Class evaluations: You will be given the opportunity to write your own evaluation of this class on UAS Online during the last three weeks that we meet. This is a big favor you are doing for me, as it helps me determine how to make the class better. If you don’t like something that is being done, please say so, but also make a suggestion for how to make it better. Course drops/withdrawals: The last day to drop this class is January 31. The last day to withdraw from this class is April 9. Please stay in touch and let me know if you cannot make it to a particular class. If I haven’t seen or heard from you in three weeks, I will check to see if you have dropped. If you haven’t, I will initiate a withdrawal to prevent my having to assign you an “F” grade. Course Schedule: Meeting Meeting 1 Jan. 18 Jan. 21 Meeting 2 Jan. 25 Jan. 28 Meeting 3 Feb. 1 Feb. 4 Meeting 4 Feb. 8 Feb. 11 Meeting 5 Feb. 15 Feb. 18 Meeting 6 Feb. 22 Feb. 25 Meeting 7 Feb. 29 Mar. 3 Meeting 8 Mar. 7 Mar. 10 Mar. 14 Mar. 17 Meeting 9 Mar. 21 Mar. 24 Meeting 10 Mar. 28 Mar. 31 Meeting 11 April 4 April 7 Lecture Topic (Wednesday) Shop safety Lab/Demonstration (Saturday) Shop safety orientation Homework Shop safety quiz Brake system components and principles Quiz #1 Brake hydraulic systems Brake system component ID and inspection Read ch. 3&4, complete all ch. quiz Inspect hydraulic systems, check proper operation & component ID Brake line fabrication and brake system bleeding Read ch. 5&6 ch. 5 review #3 & all ch. quiz- ch. 6 review #2 & all ch. quiz Read ch. 7&8, ch. 7 review #3,4,5 & all ch. quiz- ch. 8 review #1,2 & all ch. quiz Read ch. 9, complete all review and ch. quiz Quiz #2 Brake lines, fluids, and bleeding- line fabrication Quiz #3 Wheel bearings diagnosis and service Quiz #4 Drum brake components, diagnosis and service Quiz #5 Disc brake components, diagnosis and service Midterm Exam Spring Break (no classes) Parking brake & power brake systems operation & service Quiz # 6 Machining brake drums & rotors Quiz #7 ABS components and operation Wheel bearing and race diagnosis, inspection and replacement Drum brake inspection, diagnosis and repair Disc brake inspection, diagnosis and repair Read ch. 1&2, complete all ch. quiz Read ch. 10&11, complete all ch. quiz for both TBA Read ch. 12&13, ch. 12 all ch. quiz- ch. 13 review #3 & all ch. quiz Study for Midterm HAVE FUN!! Parking brake service & adjustment, power brake system inspection & service Machining demonstration and lab Read ch. 14&16, ch 14 all review & ch. quizch. 16 review 2,4 & all ch. quiz Read ch. 15, complete all ch. quiz ABS component ID & Inspection Read ch. 18, complete all review & ch. quiz Meeting 12 April 11 April 14 Meeting 13 April 18 April 21 Meeting 14 April 25 April 28 Meeting 15 May 2 Quiz #8 ABS diagnosis and service Quiz #9 Regenerative braking systems & electronic stability control Quiz #10 Review WSS testing & ABS diagnostics Read ch. 20, review # 1,2 & all ch. quiz Electronic stability control scan data retrieval & make up Read ch. 17&21, ch. 17 all ch. quiz- ch. 21 review #4, all ch. quiz Finish lab assignments Study for final Final exam (comprehensive). Cleanup lab and personal belongings.